Hydrophobic coating compositions, articles coated with said compositions, and processes for manufacturing same

Abstract

Hydrophobic coating compositions are provided as are processes to coat articles with the compositions. Extremely hydrophobic coatings are provided by the compositions. Durable, weatherable and scratch-resistant coatings are provided by compositions comprising a trifluoromethyl-containing component and a hardenable material. Weatherable coatings are also provided by compositions comprising a mobile non-volatile fluorinated component and a hardenable material. Processes are also provided for forming hydrophobic coatings on articles.

What is claimed is:  
     
       1. A composition of matter comprising: 
       a hardenable resin;  
       hydrophobic microparticles having an average particle size diameter of about 100 microns or less; and  
       a substantially nonvolatile mobile fluorinated compound that is a liquid at least one temperature in the range of from about −30° C. to about 30° C., wherein  
       the weight ratio of the hydrophobic microparticles to the hardenable resin is from 8:7 to 4:1.  
     
     
       2. A composition of matter according to  claim 1 , wherein said fluorinated compound is a perfluorinated compound. 
     
     
       3. A composition of matter according to  claim 1 , wherein said fluorinated compound is a fluoro-chloro compound. 
     
     
       4. A composition of matter according to  claim 1 , wherein said fluorinated compound is a perfluoroether. 
     
     
       5. A composition of matter according to  claim 1 , wherein said fluorinated compound is resistant to degradation by sunlight. 
     
     
       6. A composition of matter according to  claim 1 , wherein said fluorinated compound produces a surface comprising at least fifteen percent trifluoromethyl groups. 
     
     
       7. A composition of matter according to  claim 1 , wherein the melting point of said fluorinated compound is below about 30° C. 
     
     
       8. A composition of matter according to  claim 1 , wherein the melting point of said fluorinated compound is below about −20° C. 
     
     
       9. A composition of matter according to  claim 1 , wherein said fluorinated compound is substantially nonvolatile at 60° C. 
     
     
       10. A composition of matter according to  claim 1 , wherein the volume of said hardenable resin is less than the volume of said hydrophobic microparticles. 
     
     
       11. A composition of matter according to  claim 1 , wherein said microparticles comprise a polytetrafluoroethylene material, a polytetrafluoroethylene copolymer, or combinations thereof. 
     
     
       12. A composition of matter according to  claim 1 , further comprising a volatile solvent. 
     
     
       13. A composition of matter according to  claim 12 , wherein said volatile solvent is at least partially fluorinated. 
     
     
       14. A composition of matter according to  claim 1 , wherein said hardenable resin is hardenable by radiation. 
     
     
       15. A composition of matter according to  claim 1 , wherein said hardenable resin is hardenable by moisture. 
     
     
       16. A composition of matter according to  claim 1 , wherein said hardenable resin is hardenable by oxidation. 
     
     
       17. A composition of matter according to  claim 1 , wherein said hardenable resin is hardenable by the addition of a hardener or co-resin. 
     
     
       18. A composition of matter according to  claim 1 , wherein said hardenable resin is hardenable by heat. 
     
     
       19. A composition of matter according to  claim 1 , wherein said hardenable resin is hardenable by evaporation of a solvent. 
     
     
       20. A composition of matter according to  claim 1 , wherein said hardenable resin has a functionality of at least two. 
     
     
       21. A composition of matter according to  claim 1 , wherein said hardenable resin has a functionality of at least three. 
     
     
       22. A composition of matter according to  claim 1 , wherein said hardenable resin comprises at least one resin of an acrylate, an alkyd, a urethane, an isocyanate, an epoxy, a fluorocarbon, a silicone, a siloxane, a silicate, a polyester, a vinyl, an anhydride, a polyimide, a polyol, or a combination thereof. 
     
     
       23. A composition of matter according to  claim 1 , wherein said hardenable resin comprises polyhexamethylene diisocyanate. 
     
     
       24. A composition of matter according to  claim 1 , wherein said hardenable resin comprises methylene bis hexane isocyanate. 
     
     
       25. A composition of matter according to  claim 1 , wherein said hardenable resin comprises an ethoxylated acrylic. 
     
     
       26. A composition of matter according to  claim 1 , wherein said hardenable resin is weather resistant. 
     
     
       27. A composition of matter according to  claim 1 , further comprising hydrophobic nanoparticles having an average particle size diameter of less than about 100 nanometers. 
     
     
       28. A composition of matter comprising: 
       a hardenable resin;  
       hydrophobic microparticles having an average particle size diameter of about 100 microns or less; and  
       from about 1.0% by weight to about 30% by weight hydrophobic nanoparticles having an average particle size diameter of less than about 100 nanometers, based on a total non-volatile components weight of the composition.  
     
     
       29. A composition of matter according to  claim 28 , wherein said nanoparticles have an average particle size diameter of less than about 20 nanometers. 
     
     
       30. A composition of matter according to  claim 28 , wherein said microparticles comprise polytetrafluoroethylene, a polytetrafluoroethylene copolymer, or a combination thereof. 
     
     
       31. A composition of matter according to  claim 28 , further comprising a volatile solvent. 
     
     
       32. A composition of matter according to  claim 31 , wherein said volatile solvent is at least partially fluorinated. 
     
     
       33. A composition of matter according to  claim 28 , wherein said hardenable resin is hardenable by radiation. 
     
     
       34. A composition of matter according to  claim 28 , wherein said hardenable resin is hardenable by moisture. 
     
     
       35. A composition of matter according to  claim 28 , wherein said hardenable resin is hardenable by oxidation. 
     
     
       36. A composition of matter according to  claim 28 , wherein said hardenable resin is hardenable by the addition of a hardener or co-resin. 
     
     
       37. A composition of matter according to  claim 28 , wherein said hardenable resin is hardenable by heat. 
     
     
       38. A composition of matter according to  claim 28 , wherein said hardenable resin is hardenable by evaporation of a solvent. 
     
     
       39. A composition of matter according to  claim 28 , wherein said hardenable resin has a functionality of at least two. 
     
     
       40. A composition of matter according to  claim 28 , wherein said hardenable resin has a functionality of at least three. 
     
     
       41. A composition of matter according to  claim 28 , wherein said hardenable resin comprises at least one resin of an acrylate, an alkyd, a urethane, an isocyanate, an epoxy, a fluorocarbon, a silicone, a siloxane, a silicate, a polyester, a vinyl resin, an anhydride, a polyimide, a polyol, or a combination thereof. 
     
     
       42. A composition of matter according to  claim 28 , wherein said hardenable resin comprises polyhexamethylene diisocyanate. 
     
     
       43. A composition of matter according to  claim 28 , wherein said hardenable resin comprises methylene bis hexane isocyanate. 
     
     
       44. A composition of matter according to  claim 28 , wherein said hardenable resin comprises an ethoxylated acrylic. 
     
     
       45. A composition of matter according to  claim 28 , wherein said hardenable resin is weather resistant. 
     
     
       46. A composition of matter comprising: 
       a volume of hardenable resin; and  
       a volume of hydrophobic nanoparticles having an average particle size diameter of less than about 100 nanometers, wherein the volume of said hydrophobic nanoparticles is equal to or greater than the volume of said hardenable resin.  
     
     
       47. A composition of matter according to  claim 46 , wherein said volume of said nanoparticles is more than twice the volume of said hardenable resin. 
     
     
       48. A composition of matter according to  claim 46 , wherein said nanoparticles have an average particle size diameter of less than about 20 nanometers. 
     
     
       49. An article having a coating on a surface thereof, said coating comprising the composition of matter of  claim 1 . 
     
     
       50. An article according to  claim 49 , wherein said article is an article that in use is exposed to weather or the elements. 
     
     
       51. An article according to  claim 49 , wherein said article is an article that in use is intended to reflect or conduct electromagnetic radiation. 
     
     
       52. An article according to  claim 49 , wherein said article comprises a laboratory vessel or a component thereof. 
     
     
       53. An article having a coating on a surface thereof, said coating comprising the composition of matter of  claim 28 . 
     
     
       54. An article according to  claim 53 , wherein said article is an article that in use is exposed to weather or the elements. 
     
     
       55. An article according to  claim 53 , wherein said article is an article that in use is intended to reflect or conduct electromagnetic radiation. 
     
     
       56. An article according to  claim 53 , wherein said article comprises a laboratory vessel or a component thereof. 
     
     
       57. The composition of  claim 28 , comprising from about 5% by weight to about 10% by weight said hydrophobic nanoparticles. 
     
     
       58. The composition of  claim 46 , further comprising a substantially nonvolatile mobile fluorinated compound that is a liquid at at least one temperature in the range of from about −30° C. to about 30° C. 
     
     
       59. A composition of matter comprising: 
       a hardenable resin;  
       hydrophobic microparticles having an average particle size diameter of about 100 microns or less; and  
       a substantially nonvolatile mobile fluorinated compound that is a liquid at at least one temperature in the range of from about −30° C. to about 30° C., wherein the composition comprises from about 0.01% by weight to about 50% by weight said hardenable resin.  
     
     
       60. The composition of  claim 59 , wherein said composition comprises a total solids weight of from about 0.01% by weight to about 50% by weight.